Nested Metal Strip Punching with Roll Stand Contour Control
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Solution Overview
Problem
Existing methods for producing circumferentially contoured elongated blanks from metal strips fail to effectively manage thickness variations and material utilization, leading to unwanted contour deviations and inefficiencies in material use.
Innovation Solution
The method involves punching metal strips with constant thickness in a nested position to optimize material utilization, followed by individual longitudinal guidance through a roll stand with pretension to achieve varying thickness ranges, accounting for thickness tolerances to prevent contour deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If metal strips are punched in a nested position to optimize material utilization, then material waste is reduced by 10-30%, but thickness variations and contour deviations occur due to existing thickness tolerances of the metal strips
Solution Approach 1:
The patent measures the thickness of each starting blank before rolling and plans the rolling process in advance based on these measurements. This preliminary action allows the system to compensate for thickness variations by adjusting rolling parameters for each individual blank, ensuring contour precision while maintaining nested punching for material efficiency
Solution Approach 2:
The patent changes the rolling parameters (roll stand settings, pretension forces, rolling speed) based on the measured thickness of each starting blank. By dynamically adjusting these parameters according to actual thickness variations, the system produces blanks with consistent contour precision despite variations in the original metal strip thickness
2Strength
If starting blanks are rolled to form shaped blanks with different thickness ranges, then the blanks can optimally deal with stresses at different levels, but the material lengthens requiring repositioning in the nested arrangement
Solution Approach 1:
The patent implements a feedback loop where the thickness of each starting blank is measured before rolling, and this measurement information is used to adjust the rolling process and plan the final positioning. This feedback mechanism ensures that material elongation is compensated for, maintaining precise positioning and nesting arrangement while achieving the desired thickness variations for stress resistance
Solution Approach 2:
The patent plans the nested position of starting blanks in advance based on their measured thickness and predicted elongation. This preliminary positioning planning accounts for the material lengthening that will occur during rolling, ensuring that blanks are correctly positioned both before and after the rolling process
3Manufacturing precision
If pretension is applied to starting blanks during rolling, then unwanted contour deviations are avoided, but the complexity of the rolling process increases
Solution Approach 1:
The patent applies pretension forces locally and individually to each starting blank based on its specific thickness and rolling requirements. Rather than using a complex universal system, the process tailors the pretension application to each blank's needs, achieving contour precision through localized control while managing overall process complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces material waste by 10-30%, enhances economic output, and ensures precise contouring of blanks like A, B, or C pillars by accounting for material elongation and thickness variations, particularly in T-shaped configurations.
Implementation Method 1
After the initial blanks have been punched, they are then individually guided longitudinally through a roll stand, where they are rolled into shaped blanks with different thickness ranges over the length
Implementation Method 2
The starting blanks are also guided through the roll stand with pretension effective in their longitudinal direction. Suitable devices are used for this purpose. This avoids unwanted contour deviations of the finished, rolled blanks
Implementation Method 3
In order to take into account any thickness tolerances that may be present in a metal strip that is provided, the punched-out starting blanks are also measured in terms of their thickness before they are introduced into a roll stand
Data Source
Figure 1~5
AI summary
The method involves initially punching circumferential side T-shaped contoured output plates (3) that are made from a metal strip with constant thickness, in an interlocked position. The output plates are guided with a pre-load (V) acting in a longitudinal direction by a roll stand (5). The output plates are individually and longitudinally aligned afterwards by the roll stand and rolled on the roll stand to form plates (6) with thickness areas that are different over the length (L1) of the plates.